Method of forming a reusable coextruded embossed nonadhesive protective cover

ABSTRACT

A method of forming a reusable, non-adhesive protective cover is disclosed which includes extruding first and second layers of a thermoplastic film onto a rotatable cast roll. The first layer has an interior surface and an exterior surface. The second layer is extruded onto the interior surface of the first layer to form a co-extruded laminate. The second layer has an exterior surface exhibiting attachment and release capabilities such that a joint tape can be used to join adjacent sheets of the protective cover together. The co-extruded laminate is then advanced between a nip formed by an embossing roll and a rubber roll whereby the exterior surface of the first layer contacts the embossing roll to form a co-extruded embossed laminate. Lastly, the co-extruded embossed laminate is passed around at least a portion of a chill roll to cool the laminate and form the reusable, co-extruded embossed non-adhesive protective cover.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a divisional patent application of U.S. Ser. No.15/340,096, filed Nov. 1, 2016 and claims priority thereto.

FIELD OF THE INVENTION

This invention relates to a method of forming a reusable, co-extrudedembossed non-adhesive protective cover which can be used to temporarilyprotect floors, walls and other hard surfaces, especially in theconstruction industry.

BACKGROUND OF THE INVENTION

There is currently a need for a reusable, non-adhesive protective coverwhich can be used to cover floors, walls and other hard surfaces, duringconstruction, in order to protect them from being damaged. The reusable,non-adhesive protective cover must be flame retardant without utilizingpolyvinyl chloride (PVC). Polyvinyl chloride is a fire retardant butwhen it burns, it creates environmental problems.

The reusable, non-adhesive protective cover must meet a number ofinternational fire and/or flame retardant standards, such as the LossPrevention Standard 1207, the National Fire Protection AssociationStandard 701, and the British Standard 5852.

In addition to being fire and flame retardant, the reusable,non-adhesive protective cover must also exhibit the ability to stay inplace. Currently, some protective covers use an adhesive coating to keepthem in place. A major disadvantage with the adhesively coated covers isthat once the adhesive coating become fouled with dirt and dust, itreduces the ability of the adhesive to retain the cover in place.Furthermore, an adhesively coated protective cover which has beencontaminated at one job site may damage the surface it is designed toprotect at a subsequent job site.

Another consideration is that the reusable, non-adhesive protectivecover should exhibit the proper coefficient of friction and peeladhesion for the job at hand. Sometimes, it may be desirable for thesurface of the reusable, non-adhesive protective cover, which ispositioned adjacent to a floor, wall or object, to have a highcoefficient of friction with little or no peel adhesion. This isespecially true when the reusable, non-adhesive protective cover is usedto protect a glossy surface. Alternatively, in other situations, it maybe advantageous to lightly adhere the surface of the reusable,non-adhesive protective cover to an exterior surface of a threedimensional object, that may have to be moved frequently. In this case,the reusable, non-adhesive protective cover may need to have a moderatecoefficient of friction and a low peel adhesion. In still othersituations, such as when the reusable, non-adhesive protective cover isattached to a wall, there may be a need for the reusable, non-adhesiveprotective cover to have a moderate coefficient of friction and amoderate peel adhesion.

The non-contact surface of the reusable, non-adhesive protective covershould exhibit the proper attachment and release capabilities such thata joint tape can be used to join adjacent sheets of the reusable,non-adhesive protective cover together. Sometimes, two or more sheets ofthe reusable, non-adhesive protective cover will need to be joinedtogether to cover large sections of a floor or wall. Other times, it maybe necessary to join two or more sheets of the reusable, non-adhesiveprotective cover together to form a waterproof seal. When it is time toseparate the sheets of the reusable, non-adhesive protective cover, thereusable, non-adhesive protective cover should also have adequatematerial strength properties to allow the joint tape to be removedwithout tearing or damaging the reusable, non-adhesive protective cover.

In addition to the reusable, non-adhesive protective cover having theaforementioned properties and characteristics, the reusable,non-adhesive protective cover has to be capable of being manufactured inan inexpensive fashion such that it will present a cost savings to theindustry.

Now, a method of forming a reusable, non-adhesive protective cover hasbeen invented.

SUMMARY OF THE INVENTION

Briefly, this invention relates to a reusable, non-adhesive protectivecover which includes a first layer having an exterior surface designedto contact a structure or object and a second layer having an exteriorsurface designed to be spaced away from the structure or object. Each ofthe first and second layers are formed from a thermoplastic film and arejoined together to form a laminate which is free of polyvinyl chloride.Each of the first and second layers contains at least about 5% of aflame retardant. The first layer also has a static coefficient offriction (COF) of at least about 0.5. The second layer exhibitsattachment and release capabilities such that a joint tape can be usedto join adjacent sheets of the reusable, non-adhesive protective covertogether. The properties of the second layer allow the joint tape to beremoved without damaging the reusable, non-adhesive protective cover.

In another embodiment, a reusable, non-adhesive protective cover istaught which has a first layer with an exterior surface designed tocontact a structure or object and a second layer having an exteriorsurface designed to be spaced away from the structure or object. Thisreusable, non-adhesive protective cover also includes a third layerpositioned between the first and second layers. Each of the first,second and third layers are formed from a thermoplastic film and arejoined together to form a laminate which is free of polyvinyl chloride.Each of the first, second and third layers contains at least about 5% ofa flame retardant. The first layer has a static coefficient of friction(COF) of at least about 0.7. The second layer exhibits attachment andrelease capabilities such that a joint tape can be used to join adjacentsheets of the reusable, non-adhesive protective cover together. Theproperties of the second layer allow the joint tape to be removedwithout damaging the reusable, non-adhesive protective cover.

Several methods of forming a reusable, non-adhesive protective cover arealso taught. One method includes the steps of co-extruding first andsecond thermoplastic film layers onto a rotatable cast roll withprojections. The first layer has an interior surface and an exteriorsurface. The first thermoplastic film layer contains from between about5% to about 20% of a flame retardant. The first layer also has a staticcoefficient of friction (COF) of at least about 0.5. The secondthermoplastic film layer has an exterior surface exhibitingpredetermined attachment and release capabilities such that a joint tapecan be used to join adjacent sheets of the reusable, non-adhesiveprotective cover together. The second thermoplastic film layer alsocontains from between about 5% to about 20% of a flame retardant. Theco-extruded thermoplastic laminate is then advanced between a nip formedby the cast roll and a rubber roll thus forming an embossedthermoplastic laminate. Lastly, the embossed thermoplastic laminate ispassed around a portion of a chill roll to cool the thermoplasticlaminate and form the reusable, non-adhesive protective cover. Thisreusable, non-adhesive protective cover is free of polyvinyl chloride.

The general object of this invention is to provide a method of forming areusable, non-adhesive protective cover which can be used to coverfloors, walls and other hard surfaces, during construction, in order toprotect them from being damaged. A more specific object of thisinvention is to provide a method of forming a reusable, non-adhesiveprotective cover which is flame retardant.

Another object of this invention is to provide a method of forming areusable, non-adhesive protective cover which exhibits a staticcoefficient of friction of at least about 0.5 and a peel adhesion forthe job at hand.

A further object of this invention is to provide a method of forming areusable, non-adhesive protective cover which exhibits the properattachment and release capabilities such that a joint tape can be usedto join adjacent sheets of the reusable, non-adhesive protective covertogether.

Still another object of this invention is to provide a method of forminga reusable, non-adhesive protective cover which can be washed and reusedmultiple times, and which may contain protrusions which assist inunwinding a finished roll for use and which also improve the slipresistance of the protective cover when it is used to cover a floor thatmay be damp or wet.

Still further, an object of this invention is to provide a method offorming a reusable, non-adhesive protective cover which is economical tomanufacture.

Other objects and advantages of the present invention will become moreapparent to those skilled in the art in view of the followingdescription and the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a two layer reusable, non-adhesiveprotective cover.

FIG. 2 is a side view of the two layer reusable, non-adhesive protectivecover shown in FIG. 1.

FIG. 3 is a perspective view of a three layer reusable, non-adhesiveprotective cover.

FIG. 4 is a side view of the three layer reusable, non-adhesiveprotective cover shown in FIG. 3.

FIG. 5 is a perspective view of a four layer reusable, non-adhesiveprotective cover.

FIG. 6 is a side view of the four layer reusable, non-adhesiveprotective cover shown in FIG. 5.

FIG. 7 is a perspective view of a thirteen layer reusable, non-adhesiveprotective cover.

FIG. 8 is a side view of the thirteen layer reusable, non-adhesiveprotective cover shown in FIG. 7.

FIG. 9 is a top view of an embossed reusable, non-adhesive protectivecover.

FIG. 10 is a cross-sectional view of one embossment formed in thereusable, non-adhesive protective cover taken along line 10-10.

FIG. 11 is a schematic for making an embossed, coextruded film,non-adhesive protective cover.

FIG. 12 is a schematic for making an embossed, coextruded film,non-adhesive protective cover using a manifold extruder.

FIG. 13 is a schematic for making a non-embossed, coextruded film,non-adhesive protective cover.

FIG. 14 is a schematic for making a non-embossed, film extrusion coat,non-adhesive protective cover.

FIG. 15 is a schematic for making a non-embossed, coextruded film,non-adhesive protective cover.

FIG. 16 is a schematic for making an embossed, coextruded film,non-adhesive protective cover.

DETAILED DESCRIPTION OF THE INVENTION

Referring to FIGS. 1 and 2, a reusable, non-adhesive protective cover 10is shown which can be used to cover floors, walls or other hardsurfaces, during construction, in order to protect them from beingdamaged. The reusable, non-adhesive protective cover 10 can also be usedto cover any surface during a manufacturing, building or repair process.By “reusable” it is meant that the non-adhesive protective cover 10 canbe used more than once before it is discarded or recycled. By“non-adhesive” it is meant that the protective cover 10 does not includeor use any adhesive in its construction. The reusable, non-adhesiveprotective cover 10 is flame retardant, leakproof, waterproof, waterresistant, slip resistant, dust free and durable. The reusable,non-adhesive protective cover 10 can also be used in clean rooms and inhealth care environments. This reusable, non-adhesive protective cover10 can be used time and again, plus it is recyclable after its intendedlife.

Still referring to FIGS. 1 and 2, the reusable, non-adhesive protectivecover 10 is shown as a rectangular sheet having a longitudinal centralaxis X-X, a vertical central axis Y-Y and a transverse central axis Z-Z.Although depicted as a rectangular sheet, the reusable, non-adhesiveprotective cover 10 could be manufactured in a variety of geometricalshapes, including, but not limited to: a square, a circle, a triangle,etc.

The reusable, non-adhesive protective cover 10 can be constructed of twoor more layers. Desirably, the reusable, non-adhesive protective cover10 is a multi-layered structure. In the two layer embodiment, thereusable, non-adhesive protective cover 10 includes a first layer 12 anda second layer 14. The first layer 12 has an interior surface 16 and anexterior surface 18. The exterior surface 18 is designed to contact astructure or object. The exterior surface 18 is sometimes referred to asthe “contact surface”. The second layer 14 also has an interior surface20 and an exterior surface 22, The interior surface 20 of the secondlayer 14 is secured to the interior surface 16 of the first layer 12.The two interior surfaces 16 and 20 can be secured to one another bybonding, such as by using heat, by using pressure, by using acombination of heat and pressure, or by some other means known to thoseskilled in the art. The exterior surface 22 of the second layer 14 isspaced away from the structure or object which is to be covered. Theexterior surface 22 is sometimes referred to as the “non-contactsurface”.

Each of the first and second layers, 12 and 14 respectively, are formedfrom a polymer, copolymer or homopolymer into a thermoplastic film. Thefirst layer 12 can be formed from an identical material or from adifferent material which is used to form the second layer 14. Each ofthe first and second layers, 12 and 14 respectively, can be formed fromalmost any polymer, copolymer or homopolymer known to those skilled inthe art. A polymer, copolymer or homopolymer resin can be used to formthe thermoplastic film. Various processes known to those skilled in theart can be used to form a thermoplastic film from a resin. Examples oftwo processes which can be used include: a coextruded film process and amanifold co-extrusion film process. The thermoplastic film produced byeither process can be embossed or be non-embossed.

Various polyolefins can be used to create the thermoplastic film.Examples of some specific polyolefins include, but are not limited to:polypropylene, polyethylene, low density polypropylene, linear lowdensity polypropylene, high density polypropylene, low densitypolyethylene, linear low density polyethylene, high densitypolyethylene, ethylene propylene copolymer, metallocene-catalyzedpolyolefins, a styrene block copolymer, etc. For example, either of thefirst or second layers, 12 or 14 respectively, could be formed from atleast about 50% of a styrene block copolymer. Desirably, either of thefirst or second layers, 12 or 14 respectively, could be formed from atleast about 60% of a styrene block copolymer. More desirably, either ofthe first or second layers, 12 or 14 respectively, could be formed fromat least about 65% of a styrene block copolymer. Even more desirably,either of the first or second layers, 12 or 14 respectively, could beformed from about 70% of a styrene block copolymer.

Each of the first and second layers, 12 and 14 respectively, can be of ahomogeneous construction. By “homogeneous” it is meant that the layer isof the same or similar nature or kind. Alternatively, each of the firstand second layers, 12 and 14 respectively, can be of a heterogeneousconstruction where each layer is different.

The first and second layers, 12 and 14 respectively, are joined togetherto form a laminate 24. The laminate 24 can be a thermoplastic laminate.The laminate 24 has an overall thickness (not designated) which rangesfrom between about 5 mils to about 100 mils or greater, (1 mil=0.001inches). Desirably, the overall thickness of the laminate 24 can rangefrom between about 5 mils to about 80 mils. More desirably, the overallthickness of the laminate 24 can range from between about 5 mils toabout 70 mils. Even more desirably, the overall thickness of thelaminate 24 can range from between about 5 mils to about 60 mils.

The laminate 24 is free or void of any polyvinyl chloride (PVC).Polyvinyl chloride (PVC) is one of a group of polymerized thermoplasticvinyls. Polyvinyl chloride is a fire retardant but when it burns, itcreates environmental problems. PVC decomposes in the range of frombetween about 302° Fahrenheit (F) to about 572° F. PVC flash ignites at735° F. and self-ignites at 850° F. Up to about 446° F., hydrogenchloride is given off in a white mist and carbon monoxide (CO) is givenoff mainly above 482° F. From between about 752° F. to about 1,112° F.,ethylene, benzene, naphthalene, and other hydrocarbons are produced.When these products are burned with sufficient oxygen, hydrogenchloride, carbon monoxide and carbon dioxide are produced. Such toxicgases are harmful to humans. For this reason, companies have moved awayfrom manufacturing protective covers which contain polyvinyl chloride.The reusable, non-adhesive protective cover 10 is free or void of anypolyvinyl chloride.

Still referring to FIGS. 1 and 2, desirably each of the first and secondlayers, 12 and 14 respectively, contains a flame retardant. Certainchemicals or substances act as both a fire retardant and as a flameretardant. When such a chemical or substance is added to each of thefirst and second layers, 12 and 14 respectively, the first and secondlayers, 12 and 14 respectively, become resistant to catching fire and/orbursting into flame. By “fire” it is meant a chemical change thatreleases heat and light and is accompanied by flame, especially theexothermic oxidation of a combustible substance. By “fire retardant” itis meant resistant to catching fire. By “flame retardant” it is meantresistant to bursting into a flame. Each of the first and second layers,12 and 14 respectively, can contain at least about 5% of a flameretardant. Desirably, each of the first and second layers, 12 and 14respectively, contains at least about 8% of a flame retardant. Moredesirably, each of the first and second layers, 12 and 14 respectively,contains at least about 10% of a flame retardant. Even more desirably,each of the first and second layers, 12 and 14 respectively, contains atleast about 12% of a flame retardant. Most desirably, each of the firstand second layers, 12 and 14 respectively, contains from between about5% to about 20% of a flame retardant.

A good flame retardant is Extensity 0201-127 commercially sold by SacoAE Polymers, 3220 Crocker Ave., Sheboygan, Wis. 53081. Decabromodiphenylethane, such as FR-1410, is another good flame retardant. FR-1410 ismanufactured by ICL Industrial Products, having a corporate headquartersat Makeleff House, 12 Kroitzer Street, P.O. Box 180, Beer Sheva, 84101Israel.

The reusable, non-adhesive protective cover 10 is designed to meet thefollowing tests:

-   -   1. The National Fire Protection Association (NFPA) Test Method        701-2010 for flame propagation of textiles and films;    -   2. The National Fire Protection Association (NFPA) Test Method        UL 723 for flame spread and smoke developed;    -   3. The National Fire Protection Association (NFPA) Test Method        701-04 (small scale) Flammability test;    -   4. British Standard (BS)2782: part 1: Method 141: 1986, British        Standard European Norm (EN)2825 and EN2826, 135476, BS476: Part        12: 1991 Ignition Source C and Large Flame Test to Loss        Prevention Standard (LPS) 1207: 1994 Section 3.1.3;    -   5. The Federal GSA (General Services Administration) Standard        191 Method 5903—Federal Standard for textile methods—Fire        Retardant Test.

In addition, selected samples of the reusable, non-adhesive protectivecover 10 have been subjected to a series of tests utilizing the testmethodology contained in Loss Prevention Standard (LPS) 1207, issuedJanuary, 2002 by Building Research Establishment (BRE). BRE is a formerUnited Kingdom (UK) government establishment but now is a privateorganization that carries out research, consultancy and testing for theconstruction and built environment sectors in the UK. The BRE isheadquartered in Watford with regional sites in Glasgow and Swansea.Among the BRE's areas of interest are participation in the preparationof national and international standards and building codes, includingthe UK Building Regulations. The organization is now funded by incomefrom its commercial programs, the BRE bookshop, contracted work, and bybidding for research funding from government and the industries itserves. The BRE also has UKAS Accredited Testing Laboratories.

These tests included:

-   -   1. Small Flame Test—carried out to British Standard (BS) 476:        part 12, issued 1991. This test method tests building materials        and structures for ignitability by direct flame impingement. The        method uses a choice of seven flaming ignition sources for a        variety of flame application times.    -   2. Large Flame Test—using Crib No. 7 from British Standard        (BS) 5852. BS 5852 describes the best practice methods to assess        the ignitability of single material combinations, such as covers        and fillings used in upholstered seating, or complete items of        seating. These tests determine the effects of a smoldering        cigarette, or other flaming ignition sources, such as burning        matches or a four-sheet full-size newspaper. This standard can        be used to establish the potential ignitability of components in        conjunction with other specified materials. BS 5852, issued        2006, first looks at the criteria of ignition, and the health        and safety of operators. It then explains the various apparatus,        before focusing on smoldering ignition sources—such as a        cigarette, butane gas flames and flaming wooden cribs. It also        looks at ways to test for the ignitability of upholstery        composites and complete items of furniture.    -   3. Smoke & Toxic Gas Emission—using equipment and procedure as        per British Standard European Norm (EN) 2824, EN 2825, and EN        2826—Aerospace Series. This standard tests the burning behavior        of non-metallic materials under the influence of radiating heat        and flames to determine the smoke density and gas components in        the smoke of the burning materials.    -   4. Oxygen Index—carried out according to British Standard (BS)        2782, part 1: method 141; 1986. This is a widely used test which        provides a single figure related to ignitability. Limiting        Oxygen Index (LOI) is the percent concentration of oxygen at        which a small specimen will only just burn downwards in a candle        like manner. The test is probably the most well-known of the        standard fire tests. The apparatus holds a small specimen of        material which is clamped vertically in a tube in an atmosphere        where the relative concentration of oxygen and nitrogen a small        pilot flame to find the minimum oxygen concentration required to        just sustain combustion of the sample.

Referring now to FIG. 2, one will notice that the reusable, non-adhesiveprotective cover 10 has a thickness t. This thickness t can vary indimension. Desirably, the thickness t ranges from between about 5 mils(1 mil=0.001 inches) to about 100 mils, More desirably, the thickness tranges from between about 5 mils to about 80 mils. Even more desirably,the thickness t ranges from between about 5 mils to about 60 mils.

The first layer 12 of the reusable, non-adhesive protective cover 10 hasa thickness t₁. The thickness t₁ of the first layer 12 can vary indimension. Generally, the thickness t₁ of the first layer 12 ranges frombetween about 1 mil to about 10 mils. Desirably, the thickness t₁ of thefirst layer 12 ranges from between about 1 mil to about 8 mils. Moredesirably, the thickness t₁ of the first layer 12 is less than about 7mils. Even more desirably, the thickness t₁ of the first layer 12 isless than about 6 mils. Most desirably, the thickness t₁ of the firstlayer 12 is less than about 5 mils.

Still referring to FIG. 2, the second layer 14 has a thickness t₂. Thethickness t₂ of the second layer 14 can vary in dimension. Generally,the thickness t₂ of the second layer 14 is greater than the thickness t₁of the first layer 12, The thickness t₂ of the second layer 14 can rangefrom between about 1 mil to about 60 mils. Desirably, the thickness t₂of the second layer 14 can range from between about 2 mils to about 55mils. More desirably, the thickness t₂ of the second layer 14 is lessthan about 40 mils. Even more desirably, the thickness t₂ of the secondlayer 14 is less than about 30 mils, Most desirably, the thickness t₂ ofthe second layer 14 is less than about 20 mils.

In FIG. 2, the thickness t₁ of the first layer 12 is depicted as beingless than the thickness t₂ of the second layer 14. This is generally thecase. For a reusable, non-adhesive protective cover 10 constructed oftwo layers 12 and 14, the first layer 12 usually accounts for about 20%of the total thickness t when the non-adhesive protective cover 10 has atotal thickness t of about 20 mils or less. When the reusable,non-adhesive protective cover 10 has a total thickness t of greater thanabout 20 mils, the first layer 12 usually accounts for about 10% of thetotal thickness t. However, one could construct the first layer 12 sothat its thickness t₁ is equal to the thickness t₂ of the second layer14. Alternatively, the thickness t₁ of the first layer 12 could begreater than the thickness t₂ of the second layer 14, if desired.

Referring again to FIGS. 1 and 2, the first layer 12 has a high average,static coefficient of friction (SCOF) as measured by the AmericanSociety for Testing and Materials (ASTM) C1 028-96, anti-slip, anti-skidtest. The first layer 12 has a SCOF of at least about 0.5. Desirably,the first layer 12 has a SCOF of at least about 0.7. More desirably, thefirst layer 12 has a SCOF of at least about 1.0. Even more desirably,the first layer 12 has a SCOF of at least about 1.5. Most desirably, thefirst layer 12 has a SCOF of at least about 2.0.

The coefficient of friction (COF), often symbolized by the Greek letterμ, is a dimensionless scalar value which describes the ratio of theforce of friction between two bodies and the force pressing themtogether. The coefficient of friction depends on the materials used: forexample, ice on steel has a low coefficient of friction, while rubber onpavement has a high coefficient of friction. Coefficients of frictionrange from near zero to greater than one. Arthur Morin introduced theterm and demonstrated the utility of the coefficient of friction. Thecoefficient of friction is an empirical measurement—it has to bemeasured experimentally, and cannot be found through calculations.Rougher surfaces tend to have higher effective values. Both static andkinetic coefficients of friction depend on the pair of surfaces incontact: for a given pair of surfaces, the static coefficient offriction is usually larger than the kinetic coefficient of friction. Insome sets, the two coefficients are equal, such as Teflon on Teflon.

Most dry materials have a coefficient of friction (COF) value rangingfrom between about 0.3 to about 0.6. Values outside this range arerarer, but Teflon, for example, can have a coefficient of friction (COF)value as low as 0.04. A value of zero would mean no friction at all, anelusive property. Rubber in contact with other surfaces can yieldcoefficient of friction (COF) values of from between about 1 to about 2.Occasionally, it is maintained that μ is always less than 1, but this isnot true. While in most relevant applications μ is less than 1, a valueabove 1 merely implies that the force required to slide an object alongthe surface is greater than the normal force of the surface on theobject. For example, silicone rubber or acrylic rubber-coated surfaceshave a coefficient of friction (COF) that can be substantially largerthan 1.

While it is often stated that the COF is a “material property”, it isbetter categorized as a “system property”. Unlike true materialproperties (such as conductivity, dielectric constant, yield strength),the COF for any two materials depends on system variables liketemperature, velocity, atmosphere and also what are now popularlydescribed as aging and de-aging times; as well as on geometricproperties of the interface between the materials. For example, a copperpin sliding against a thick copper plate can have a COF that varies from0.6 at low speeds (metal sliding against metal) to below 0.2 at highspeeds when the copper surface begins to melt due to frictional heating.The latter speed of course, does not determine the COF uniquely; if thepin diameter is increased so that the frictional heating is removedrapidly, the temperature drops, the pin remains solid and the COF risesto that of a “low speed” test.

Various chemicals, substances, polymers, copolymers or elastomers can beadded to the first layer 12 to increase the COF. Kraton® is a styreneblock copolymer that can be added to increase the COF of the first layer12. Kraton® is a registered trademark of Shell Oil Company having anoffice at One Shell Plaza, 910 Louisiana, Houston, Tex. 77002. “KRATONand a logo” is also a registered trademark for a number of highperformance elastomers manufactured by Kraton Performance Polymers, Inc.having an office at 15710 John F. Kennedy Boulevard, Suite 300. Houston,Tex. 77032-2347. Kraton® polymers offer many of the properties ofnatural rubber, such as flexibility, high traction, and sealingabilities, but increased resistance to heat, weathering, and chemicals.Vistamaxx™ is another polymer which can be added to increase the COF ofthe first layer 12. Vistamaxx™ is commercially available from ExxonMobil Corporation having an office at 5959 Las Colinas Boulevard,Irving, Tex. 75039-2298.

It should be noted that there is no need to increase the staticcoefficient of friction (SCOF) of the second layer 14 since it will bespaced away from the structure or object being covered.

The first layer 12 can contain from between about 10% to about 80% ofKraton®. Desirably, the first layer 12 contains from between about 20%to about 75% of Kraton®. More desirably, the first layer 12 containsfrom between about 30% to about 70% Kraton®. Even more desirably, thefirst layer 12 contains at least about 40% Kraton®. Most desirably, thefirst layer 12 contains at least about 50% Kraton®.

The first layer 12 can be constructed to have a peel adhesion, alsoknown as peel strength. By “peel adhesion” it is meant a measure of theaverage force needed to separate two bonded materials, like tape,labels, textile or plastic films. The peel adhesion is calculated duringa peel test at a constant speed rate by dividing the average forcerequired during the test by the unit width of the bonded samples.Depending on materials, norms, products, etc., the tests can be donewith different angles; 90° and 180° are commonly used. The peel adhesionof the first layer 12 can vary. The peel adhesion of the first layer 12can be calculated using the American Society for Testing and Materials(ASTM) D3330-04, Method A—180° test. The sample width for peel testingwas 1 inch wide. The Peak Load and the Average Peak Load is reported inNewtons (N) and relates to the 1 inch wide sample. The Peel Strength(adhesion) is calculated by dividing the Average Peak Load by 25.

Five samples of the first layer 12 of the reusable, non-adhesiveprotective cover 10 were tested for peel adhesion. The results were asfollows:

Peak Load Average Peak Load Peel Strength (N) (N) (N/mm) Sample No. 14.488 1.600 0.064 2 3.808 1.789 0.072 3 5.467 1.589 0.064 4 7.898 2.6670.107 5 3.497 1.448 0.058 Summary: Minimum: 3.497 1.448 0.058 Maximum:7.898 2.667 0.107 Average: 5.032 1.819 0.073 Std. Dev. 1.772 0.490 0.02

These test results show that the 180 degree peel strength needed toremove the first layer 12 from stainless steel was at least about 0.04Newtons/mm. Desirably, the Peak strength needed to remove the firstlayer 12 from stainless steel was at least about 0.05 Newtons/mm. TheAverage Peak Load needed to remove the first layer 12 from stainlesssteel was at least about 3.4 Newtons. Desirably, the Average Peak Loadneeded to remove the first layer 12 from stainless steel was at leastabout 5 Newtons.

Five samples of Duct (joint) tape attached to the exterior layer 22 ofthe second layer 14 of the reusable, non-adhesive protective cover 10were also tested for peel adhesion. The results were as follows:

Peak Load Average Peak Load Peel Strength (N) (N) (N/mm) Sample No. 60.137 6.786 3.413 7 0.234 10.860 5.852 8 0.161 8.418 4.020 9 0.163 8.3204.072 10  0.156 9.186 3.903 Summary: Minimum: 0.137 6.786 3.413 Maximum:0.234 10.860 5.852 Average: 0.170 8.714 4.252 Std. Dev. 0.037 1.4820.932

These test results show that the 180 degree Peel adhesion needed toremove the Duct (joint) tape from the exterior surface 22 of the secondlayer 14 were at least about 0.12 N/mm. Desirably, the 180 degree Peeladhesion needed to remove the Duct (joint) tape from the exteriorsurface 22 of the second layer 14 was at least about 0.13 N/mm. Thesetest results also show that the Peak Load needed to remove the Duct(joint) tape from the exterior surface 22 of the second layer 14 were atleast about 6.7 Newtons. The Average Peak Load needed to remove the Duct(joint) tape from the exterior surface 22 of the second layer 14 were atleast about 8 Newtons. Desirably, the Average Peak Load needed to removethe Duct (joint) tape from the exterior surface 22 of the second layer14 was at least about 8.5 Newtons.

These test results show that the Peak Load needed to remove the Duct(joint) from the exterior surface 22 of the second layer 14 were atleast about 6.7 Newtons. The Average Peak Load needed to remove the Duct(joint) tape from the exterior surface 22 of the second layer 14 was atleast about 8 Newtons. Desirably, the Average Peak Load needed to removethe Duct (joint) tape from the exterior surface 22 of the second layer14 was at least about 8.5 Newtons.

By “peel adhesion” it is meant a measure of the average force needed toseparate two bonded materials. The force needed to tear the reusable,non-adhesive protective cover 10 is higher than the measured MaximumPeak Load. Desirably, the force needed to tear the reusable,non-adhesive protective cover 10 is well above the Maximum Peak Load.

A “Tear Propagation Resistance Test” was performed on all ten samplesaccording to ASTM D1938-14. Three (3) thickness measurements were takenin the center of each sample. These three measurements were averaged andthe average value used as the sample thickness for conducting the test.

The test samples were installed between two grips and a crosshead rateof 250 millimeters per minute was used to tear the samples at thenotches. The initiation load, peak load, average load, and extension atpeak load were recorded. The results are shown below:

Avg. Avg. Avg. Of Avg. Ext. Initiation Peak Avg. at Peak Sample LoadLoad Load Load No's Designation (N) (N) (N) (mm) 1-5  Machine Direction31.74 54.58 33.61 88.12 6-10 Transverse Direction 32.69 58.86 35.9091.65

The test data showed the following for ‘Machine Direction’—samples 1-5,and “Transverse Direction”—samples 6-10.

Machine Direction Average Initial Peak Extension at Sample Thickness(mm) Load Tear Load Load Peak Load No. 1st 2nd 3rd Average (N) (N) (N)(N) 1 0.880 0.860 0.915 0.885 31.60 38.47 46.11 84.48 2 0.887 0.9070.877 0.890 35.77 36.98 58.24 97.17 3 0.940 0.841 0.927 0.903 36.7026.10 55.49 97.58 4 0.897 0.860 0.903 0.887 32.51 26.25 69.37 102.8 50.885 0.905 0.881 0.890 31.47 30.73 43.68 58.59 Minimum: 0.885 31.4726.10 43.68 58.59 Maximum: 0.903 36.70 38.47 69.37 102.8 Average: 0.89133.61 31.71 54.58 88.12 Std. Dev. 0.007 2.450 5.820 10.29 17.83

Transverse Direction Average Initial Peak Extension at Sample Thickness(mm) Load Tear Load Load Peak Load No. 1st 2nd 3rd Average (N) (N) (N)(N) 6 0.905 0.937 0.889 0.910 33.06 30.50 54.71 88.38 7 0.891 0.9140.936 0.914 40.23 33.68 62.11 88.62 8 0.896 0.932 0.925 0.918 31.3531.77 46.19 63.56 9 0.940 0.936 0.906 0.927 44.81 42.65 78.87 116.4 100.951 0.903 0.933 0.929 30.04 24.87 52.41 101.3 Minimum: 0.910 30.0424.87 46.19 63.56 Maximum: 0.929 44.81 42.65 78.87 116.4 Average: 0.92035.90 32.69 58.86 91.65 Std. Dev. 0.008 6.350 6.460 12.55 19.46

For the “Machine Direction”, the Average Peak Load was 54.58 Newtons,and for the “Transverse Direction” the Average Peak Load was 58.86Newtons,

To minimize the possibility of tearing the film when removing Duct(joint) tape preferably, the tear propagation average initiation loadshould be at least 2 times the Average Peak Load needed to remove theDuct (joint) tape from the exterior surface 22 of the second layer 14,or 2×8.714=17.4 N. More preferably, the tear propagation averageinitiation load should be at least 2.5 times the Average Peak loadneeded to remove the Duct (joint) tape from the exterior surface 22 ofthe second layer 14, or 2.5×8.714=21.8 N, Most preferably, the tearpropagation average initiation load should be at least 3 times theAverage Peak Load needed to remove the Duct (joint) tape from theexterior surface 22 of the second layer 14, or 3×8.714=26.1 N.

Stated another way, the protective cover 10 has a tear propagationinitial load which is higher than the peak load.

Still referring to FIGS. 1 and 2, the first and second layers, 12 and 14respectively, can also contain a colorant (not shown). The use of acolorant is optional, Various colorants are commercially available froma number of vendors, One such colorant is 16572 Blue available fromAmpacet Corporation, 660 White Plains Road, Tarrytown, N.Y. 10591.Generally, less than about 3% of the composition of each of the firstand second layers, 12 and 14 respectively, is made up of the colorant.Desirably, the colorant in each of the first and second layers, 12 and14 respectively, ranges from between about 0.5% to about 1.75%. Moredesirably, the colorant in each of the first and second layers, 12 and14 respectively, ranges from between about 0.75% to about 1.6%. Evenmore desirably, the colorant in each of the first and second layers, 12and 14 respectively, ranges from between about 0.8% to about 1.5%. Mostdesirably, less than about 1% of the composition of each of the firstand second layers, 12 and 14 respectively, is made up of the colorant.

The first layer 12 has the ability to stay in place during use. It ismade to contact the surface of the structure or object that needs to beprotected. The first layer 12 can have a moderate to a high staticcoefficient of friction (SCOF) value to assure that it stays in placeand is slip resistant. The first layer 12 is also capable of beingrinsed, washed or refreshed after each use. Since the first layer 12 isformed from a film, it can be rinsed with water to remove anycontaminants that may have come in contact with it. When the first layer12 is formed from metallocene-catalyzed polyolefin polymers, ethylenecopolymers and/or styrenic block copolymers, washing will quickly removeany contaminates.

It should be understood that the composition of the first layer 12 canvary. Normally, the first layer 12 will include from about 10% to about30% of a polymer; from about 50 to about 80% of a chemical to increaseSCOF, such as Kraton®; from about 10% to about 15% of a flame retardant,such as Extensity 0201-127; and from about 0.5% to about 3% of acolorant. When the polymer is a copolymer, the composition of the twocomponents can be equal or can vary. Normally, the composition of acopolymer will vary. For example, a copolymer can include about 60% toabout 95% of low density polyethylene and from about 5% to about 40% oflinear low density polyethylene.

In one example, the first layer 12 can include about 18% polyethylene,about 70% Kraton MD6666GO, from about 10% to about 15% of a flameretardant, and from about 0.5% to about 2% of a colorant.

By varying the composition of the polymer, copolymer or homopolymer usedin the first layer 12, and by varying the additional chemical orsubstances added to the first layer 12, such as Kraton® and Extensity0201-127, one can alter the static coefficient of friction (SCOF) andpeel adhesion of the reusable, non-adhesive protective cover 10, Forexample, certain grades of metallocene-catalyzed polymers deliver a highstatic coefficient of friction (SCOF) with little or no peel adhesion.Kraton MD6741 produces a film with a high static coefficient of friction(SCOF) and a low level of peel adhesion, Kraton MD6748 produces a filmwith a high level of a static coefficient of friction (SCOF) and a highlevel of peel adhesion. Therefore, it is possible to adjust thecomposition of the first layer 12 to deliver the desired staticcoefficient of friction (SCOF) and peel adhesion needed for a particularjob.

Still referring to FIGS. 1 and 2, the second layer 14 of the reusable,non-adhesive protective cover 10 is also formed from a polymer;copolymer or homopolymer. The second layer 14 can use the same or adifferent polymer, copolymer or homopolymer as was used to create thefirst layer 12. The second layer 14 does not have to have a moderate orhigh static coefficient of friction (SCOF) value and therefore nochemical or substance, such as Kraton®, has to be added to the secondlayer 14. The second layer 14 does have from about 10% to about 15% of aflame retardant, Like in the first layer 12, a flame retardant such asExtensity 0201-127 can be added to the second layer 14 to make it flameretardant. The second layer 14 is also water proof or water resistantsince it is made from a thermoplastic material. The second layer 14 canbe glossy, if desired. By “glossy” it is meant having a smooth shinylustrous surface, A glossmeter (also gloss meter) is an instrument whichis used to measure specular reflection gloss of a surface. Gloss isdetermined by projecting a beam of light at a fixed intensity and angleonto a surface and measuring the amount of reflected light at an equalbut opposite angle. The measurement results of a glossmeter are relatedto the amount of reflected light from a black glass standard with adefined refractive index, and not to the amount of incident light. Themeasurement value for this defined standard is equal to 100 gloss units(calibration). Materials with a higher refractive index can have ameasurement value above 100 gloss units (GU), e.g. films. In case oftransparent materials, the measurement value can be increased due tomultiple reflections in the bulk of the material. The exterior surface22 of the second layer 14 can have a gloss refractive index of greaterthan about 100 gloss units.

The second layer 14 can make up at least about 50% of the basis weightof the reusable, non-adhesive protective cover 10. Desirably, the secondlayer 14 can make up at least about 60% of the basis weight of thereusable, non-adhesive protective cover 10. More desirably, the secondlayer 14 can make up at least about 70% of the basis weight of thereusable, non-adhesive protective cover 10.

Referring again to FIGS. 1 and 2, the thickness t₂ of the second layer14 is generally greater than the thickness t₁ of the first layer 12. Asdepicted, the thickness t₂ of the second layer 14 is at least about twotimes the thickness t₁ of the first layer 12. Desirably, the thicknesst₂ of the second layer 14 is at least about three times the thickness t₁of the first layer 12.

The surface energy of the exterior surface 22 of the second layer 14should be such that it allows proper release from a joint tape, such asDuct tape, without damaging the reusable, non-adhesive protective cover10 while at the same time providing a waterproof attachment to adjacentsheets of the reusable, non-adhesive protective cover 10. The lowsurface energy of the exterior surface 22 of the second layer 14 reducesthe wetting out or attraction of the Duct (joint) tape adhesive to theexterior surface 22. Desirably, the exterior surface 22 of the secondlayer 14 has a surface energy of less than about 45 dynes/cm, Moredesirably, the exterior surface 22 of the second layer 14 has a surfaceenergy of less than about 40 dynes/cm. Even more desirably, the exteriorsurface 22 of the second layer 14 has a surface energy of less thanabout 35 dynes/cm. Surface energy is determined by the use of dyne testpens, such Accu Dyne test pens, made by Diversified Enterprises, 101Mulberry Street, Suite 2N, Claremont, N.H. 03743.

The reusable, non-adhesive protective cover 10 has a predetermined basisweight and the second layer 14 can make up at least about 70% of thebasis weight of the reusable, non-adhesive protective cover 10.Desirably, the second layer 14 can make up at least about 75% of thebasis weight of the reusable, non-adhesive protective cover 10. Moredesirably, the second layer 14 can make up at least about 80% of thebasis weight of the reusable, non-adhesive protective cover 10.

As the percent of the basis weight of the reusable, non-adhesiveprotective cover 10 that comes from the second layer 14 increases, thecost of the first layer 12 decreases because the cost of the Kraton®film in the first layer 12 is significantly more costly than the cost ofthe polymers (polyethylene) used to form the second layer 14. Forexample, if the weight of a section of the reusable, non-adhesiveprotective cover 10 is 10 pounds, and the polymers in the second layer14 weigh 7 pounds, at a cost of $0.20 per pound, then the cost of thesecond layer 14 is (7×$0,20)=$1.40. The weight of the first layer 12 is3 pounds and the cost of the polymers in the first layer 14 is $1.00 perpound (3×1.00)=$3.00. Therefore, the total cost of the 10 pound sampleof the reusable, non-adhesive protective cover 10 is($1,40+$3,00)=$4.40, Whereas, if the second layer 14 of a 10 poundsample of a non-adhesive protective cover 10 weighs 8 pounds, then thecost of the second layer 14 is (8×$0.20)=$1.60. The weight of the firstlayer 12 is 2 pounds and the cost of the polymer in the first layer 12is $1.00 per pound (2×$1,00)=$2.00, Therefore, the total cost of the 10pound sample of the reusable, non-adhesive protective cover 10 is(1.60+$2.00)=$3.60.

The composition of the second layer 14 should also exhibit “attachmentand release” capabilities such that a joint tape (not shown) can be usedto join adjacent sheets of the reusable, non-adhesive protective cover10 together. The joint tape can vary in construction. The joint tape canbe a Duct type tape having a predetermined peel adhesion value. 3MCompany having an office at 3M Center Building 220 in Saint Paul, Minn.55144 is one company that sells a number of different kinds of Duct(joint) tapes. Three such Duct (joint) tapes from 3M Company arenumbers: 3903, 3939 and 6969. Each has a specific peel adhesion valuecalculated according to the American Society for Testing and Materials(ASTM)—D3330, The tape 3903 has an adhesion to steel of 16 ounces/inchwidth; the tape 3939 has an adhesion to steel of 55 ounces/inch width;and the tape 6969 has an adhesion to steel of 51 ounces/inch width. Itis important that the Duct (joint) tape can be adhered to the exteriorsurface 22 of the second layer 14 and be later removed from the secondlayer 14 without damaging the reusable, non-adhesive protective cover10, Desirably, the reusable, non-adhesive protective cover 10 will nottear as the Duct (joint) tape is removed.

It should be understood that achieving the proper surface energy in theexterior surface 22 of the second layer 14 is an important factor inachieving proper adhesion when joining two adjacent sheets of thereusable, non-adhesive protective covers 10, 10 together. Two or moresheets of the reusable, non-adhesive protective cover 10, 10 may bejoined together in order to cover a larger area. A joint tape, such asDuct tape, can be used to secure two or more sheets of the reusable,non-adhesive protective cover 10, 10 together. If the surface energy ofthe exterior surface 22 of the second layer 14 is too low, and thesurface energy of the Duct (joint) tape is not high enough tocompensate, the Duct (joint) tape will not adhere properly to theexterior surface 22 of the second layer 14. If the surface energy of theexterior surface 22 of the second layer 14 is too high, and the surfaceenergy of the Duct (joint) tape is not lowered enough to compensate, theDuct (joint) tape will not release properly from the exterior surface 22and this may result in tearing the reusable, non-adhesive protectivecover 10. A proper balance of surface energy between the exteriorsurface 22 of the second layer 14 and the Duct (joint) tape adhesivesurface will ensure that the Duct (joint) tape can be removed withoutdamaging the reusable, non-adhesive protective cover 10.

Another factor which can improve the usable life of the reusable,non-adhesive protective cover 10 is the “tear resistance” of thethermoplastic film from which the second layer 14 is constructed. By“tear resistance” it is meant how well a material can withstand theeffects of tearing. More specifically, it is how well a material resiststhe growth of any cuts when under tension, it is usually measured inkN/m. The thermoplastic film forming the second layer 14 must have a“tear resistance” which is at least as high as the “peel adhesion” ofthe Duct (joint) tape to the reusable, non-adhesive protective cover 10,By “peel adhesion” it is meant the force required to remove a jointtape, such as Duct tape, from a test panel, such as the exterior surface22 of the second layer 14 of the reusable, non-adhesive protective cover10, The peel adhesion test is performed according to the ASTM D3330-04(2010) test procedure. The Peak Load of Duct (joint) tape attached tothe exterior surface 22 of the second layer 14 should be at least about6.7 Newtons and the Average Peak Load should be at least about 8Newtons.

It should be understood that the reusable, non-adhesive protective cover10, 10′, 10″ and 11 can be formed such that the exterior surface 18 ofthe first layer 12 and the exterior surface 22 of the second layer 14can be planar. Alternatively, the reusable, non-adhesive protectivecover 10, 10′, 10″ and 11 could be formed such that the exterior surface18 of the first layer 12 contains a plurality of indentations 52 and theexterior surface 22 of the second layer 14 contains a plurality ofprotrusions 54, see FIG. 10.

It should also be understood that the exteriors surfaces, 18 and 22respectively, of the reusable, non-adhesive protective cover 10, 10′,10″ and 11 are washable. By “washable” it is meant that thethermoplastic film is washable with water. Desirably, the reusable,non-adhesive protective cover 10, 10′, 10″ and 11 can be constructed tobe leakproof, waterproof or water resistant. By “leakproof” it is meantwater cannot pass through it. By “waterproof” it is meant that theprotective cover 10, 10′, 10″ and 11 are impervious to or unaffected bywater, By “water resistant” it is meant that the protective cover 10,10′, 10″, and 11 are water repellent.

Referring now to FIGS. 3 and 4, a reusable, non-adhesive protectivecover 10′ is shown that includes three layers. The three layers includea first layer 12, a second layer 14 and a third or middle layer 26. Thethird or middle layer 26 is positioned between the first and secondlayers, 12 and 14 respectively. The third or middle layer 26 contactsthe interior surface 16 of the first layer 12 and the interior surface20 of the second layer 14, The third or middle layer 26 can be formedfrom the same material or from a different material as was used tocreate the first and/or second layers, 12 or 14 respectively. The thirdor middle layer 26 could be formed from a polymer, a copolymer or ahomopolymer. The third or middle layer 26 does not have to have amoderate or high static coefficient of friction (SCOF) value andtherefore no chemical or substance, such as Kraton®, has to be added tothe third or middle layer 26. The third or middle layer 26 can contain aflame retardant, if desired. The presence of a flame retardant isoptional. When a flame retardant is desired, Extensity 0201-127 or someother flame retardant chemical or substance can be added to the third ormiddle layer 26. The amount of a flame retardant that can be added tothe third or middle layer 26 can vary. Normally, at least about 5% of aflame retardant can be added to the third or middle layer 26. Desirably,at least about 8% of a flame retardant can be added to the third ormiddle layer 26. More desirably, at least about 10% of a flame retardantcan be added to the third or middle layer 26, Even more desirably, atleast about 12% of a flame retardant can be added to the third or middlelayer 26, Most desirably, from between about 5% to about 20% of a flameretardant can be added to the third or middle layer 26.

It should be understood that usually the thinner a layer is, the higherpercent of a flame retardant it can contain. For example, a layer havinga thickness of about 6 mils may contain about 20% of the flameretardant, while a layer having a thickness of about 35 mils may containfrom between about 5% to about 15% of a flame retardant.

The third or middle layer 26 has a thickness t₃, see FIG. 4, which canvary in dimension. The thickness t₃ of the third or middle layer 26 canbe less than, equal to, or be greater than either of the thicknesses t₁or t₂ of the first or second layers, 12 or 14 respectively, Normally,the thickness t₃ of the third or middle layer 26 is greater than eitherof the thicknesses t₁ or t₂ of the first or second layers, 12 or 14respectively. The thickness t₃ of the third or middle layer 26 can rangefrom between about 1 mil to about 30 mils, Desirably, the thickness t₃of the third or middle layer 26 is greater than about 5 mils, Moredesirably, the thickness t₃ of the third or middle layer 26 is greaterthan about 10 mils. Even more desirably, the thickness t₃ of the thirdor middle layer 26 is greater than about 20 mils. Most desirably, thethickness t₃ of the third or middle layer 26 is less than about 30 mils.

The third or middle layer 26 can be formed from any polymer, copolymer,homopolymer or from any other material known to those skilled in theart. The third or middle layer 26 can be made from a low cost material,such as a recycled polymer, to reduce the total cost of the reusable,non-adhesive protective cover 10′. The third or middle layer 26 can alsobe made from a low basis weight material. Alternatively, the third ormiddle layer 26 can be foam. One such foam is formed from polyethylene,which will increase the overall thickness of the reusable, non-adhesiveprotective cover 10′ while keeping the overall basis weight low.Normally, as one reduces the overall basis weight of the reusable,non-adhesive protective cover 10′, one reduces the cost to manufacturethe reusable, non-adhesive protective cover 10′.

Referring again to FIG. 4, the first layer 12 can form about 20% of theoverall thickness of the reusable, non-adhesive protective cover 10′,the second layer 14 can form about 30% of the overall thickness of thereusable, non-adhesive protective cover 10′, and the third layer 26 canform about 50% of the overall thickness of the reusable, non-adhesiveprotective cover 10′.

Still referring to FIGS. 3 and 4, the reusable, non-adhesive protectivecover 10′ is similar to the reusable, non-adhesive protective cover 10,shown in FIGS. 1 and 2, except that it has three layers 12, 14 and 26,instead of the two layers 12 and 14, The reusable, non-adhesiveprotective cover 10′ is also shown as a rectangular sheet having alongitudinal central axis X-X, a vertical central axis Y-Y and atransverse central axis Z-Z. Although depicted as a rectangular sheet,the reusable, non-adhesive protective cover 10′ could be manufactured ina variety of geometrical shapes, including, but not limited to: asquare, a circle, a triangle, etc.

In the reusable, non-adhesive protective cover 10′, the exterior surface18 of the first layer 12 is designed to contact a structure or objectand is sometimes referred to as the “contact surface”, The exteriorsurface 22 of the second layer 14 is spaced away from the structure orobject which is to be covered and is sometimes referred to as the“non-contact surface”.

The third or middle layer 26 can also contain a colorant, if desired.When desired, from between about 0.5% to about 3% of a colorant can beadded to the third or middle layer 26.

The third or middle layer 26 can have a basis weight which varies. Thebasis weight of the third or middle layer 26 can range from betweenabout 40% to about 60% of the total basis weight of the reusable,non-adhesive protective cover 10′. Desirably, the basis weight of thethird or middle layer 26 can range from between about 45% to about 55%of the total basis weight of the reusable, non-adhesive protective cover10′. More desirably, the basis weight of the third or middle layer 26 isabout 50% of the total basis weight of the reusable, non-adhesiveprotective cover 10′.

The following Tables 1 and 2 will be explained with reference todifferent embodiments of a reusable, non-adhesive protective cover 10and 10′.

TABLE 1 A FILM COMPOSITION FOR A TWO LAYER FILM HIGH COF BOTTOM LAYERLOW COF TOP LAYER FILM % OF TOTAL Hydrogenated % OF TOTAL THICKNESS FILMBASIS Sytrenic Block Flame FILM BASIS Flame (INCHES) WGT LDPE LLDPECopolymer Retardant COLOR WGT LDPE LLDPE Retardant COLOR 0.005 20%20.00% 0.00% 70.00% 10.00% 0.00% 80% 76% 10% 10% 3% 0.01 20% 18.00%0.00% 70.00% 12.00% 0.00% 80% 79% 10% 10% 1% 0.02 15% 18.00% 0.00%70.00% 12.00% 0.00% 85% 79% 10% 10% 1% 0.04 15% 18.00% 0.00% 70.00%12.00% 0.00% 85% 79% 10% 10% 1% 0.06 10% 18.00% 0.00% 70.00% 12.00%0.00% 90% 79% 10% 10% 1%

TABLE 2 A FILM COMPOSITION FOR A THREE LAYER FILM HIGH COF BOTTOM LAYERMIDDLE LAYER FILM % OF TOTAL Hydrogenated % OF TOTAL THICKNESS FILMBASIS Sytrenic Block Flame FILM BASIS (INCHES) WGT LDPE LLDPE CopolymerRetardant COLOR WGT LDPE LLDPE 0.005 20% 20.00% 0.00% 70.00% 10.00%0.00% 50% 32% 15% 0.01 20% 18.00% 0.00% 70.00% 12.00% 0.00% 50% 34% 15%0.02 15% 18.00% 0.00% 70.00% 12.00% 0.00% 50% 34% 15% 0.04 15% 18.00%0.00% 70.00% 12.00% 0.00% 50% 34% 15% 0.06 10% 18.00% 0.00% 70.00%12.00% 0.00% 50% 34% 15% FILM MIDDLE LAYER LOW COF TOP LAYER THICKNESSRecycled Flame % OF TOTAL Flame (INCHES) Content Retardant COLOR FILMBASIS WGT LDPE LLDPE Retardant COLOR 0.005 40% 10% 3% 30% 72% 10% 15% 3%0.01 40% 10% 1% 30% 74% 10% 15% 1% 0.02 40% 10% 1% 35% 74% 10% 15% 1%0.04 40% 10% 1% 35% 74% 10% 15% 1% 0.06 40% 10% 1% 40% 74% 10% 15% 1%

Referring now to FIGS. 5 and 6, a reusable, non-adhesive protectivecover 10′ is shown that includes four layers. The four layers include afirst layer 12, a second layer 14, a third layer 26 and a fourth layer28. The third and fourth layers, 26 and 28 respectively, are positionedbetween the first and second layers, 12 and 14 respectively. A surfaceof the third layer 26 contacts the interior surface 16 of the firstlayer 12 and a surface of the fourth layer 28 contacts the interiorsurface 20 of the second layer 14. The third and fourth layers, 26 and28 respectively, can be formed from the same or a different material,i.e, polymer, copolymer or homopolymer, as was used to create either ofthe first or second layers, 12 or 14 respectively. The third and fourthlayers, 26 and 28 respectively, do not have to have a moderate or highstatic coefficient of friction (SCOF) value and therefore no chemical orsubstance, such as Kraton®, has to be added to either of the third orfourth layers, 26 or 28 respectively. The third and/or fourth layers, 26and/or 28 respectively, can contain a flame retardant, if desired. Thepresence of a flame retardant is optional. When a flame retardant isdesired, Extensity 0201-127 or some other flame retardant chemical orsubstance can be added to the third and/or fourth layers 26 and/or 28respectively. The amount of the flame retardant that is added can vary.Normally, at least about 5% of a flame retardant can be added to eitherof the third and/or fourth layers 26 and/or 28 respectively. Desirably,at least about 8% of a flame retardant can be added to either of thethird and/or fourth layers 26 and/or 28 respectively. More desirably, atleast about 10% of a flame retardant can be added to either of the thirdand/or fourth layers 26 and/or 28 respectively. Even more desirably, atleast about 12% of a flame retardant can be added to either of the thirdand/or fourth layers 26 and/or 28 respectively. Most desirably, eitherof the third and/or fourth layers, 26 and/or 28 respectively, cancontain from between about 5% to about 20% of a flame retardant.

The third layer 26 has a thickness t₃ and the fourth layer 28 has athickness t₄, see FIG. 6. Both of the thicknesses t₃ and t₄ can vary indimension. The thicknesses t₃ and t₄ of the third and fourth layers, 26and 28 respectively, can be less than, equal to or be greater thaneither of the thicknesses t₁ or t₂ of the first or second layers, 12 or14 respectively. Normally, both of the thicknesses t₃ and t₄ are greaterthan either of the thicknesses t₁ or t₂ of the first or second layers,12 or 14 respectively. Each of the thicknesses t₃ and t₄ can range frombetween about 5 mils to about 60 mils (about 0.005 inches to about 0.060inches). Desirably, each of the thicknesses t₃ and t₄ is greater thanabout 5 mils. More desirably, each of the thicknesses t₃ and t₄ rangesfrom between about 6 mils to about 50 mils. Even more desirably, each ofthe thicknesses t₃ and t₁ ranges from between about 6 mils to about 30mils. Most desirably, each of the thicknesses t₃ and t₄ is less thanabout 30 mils.

Stated another way, the combined thickness of the third and fourthlayers, 26 and 28 respectively, can be about 50% of the total thicknessof the reusable, non-adhesive protective cover 10″. Desirably, each ofthe third and fourth layers, 26 and 28 respectively, is about 25% of thetotal thickness of the reusable, non-adhesive protective cover 10″.

The third and/or fourth layers, 26 and/or 28 respectively, can be formedfrom any polymer, copolymer, homopolymer or from any other materialknown to those skilled in the art. The third and/or fourth layers, 26and/or 28 respectively, can be made from a low cost material, such as arecycled polymer, to reduce the total cost of the reusable, non-adhesiveprotective cover 10″. Alternatively, the third and/or fourth layers, 26and/or 28 respectively, can be foam. One such foam is formed frompolyethylene, which will increase the overall thickness of the reusable,non-adhesive protective cover 10″ while keeping the overall basis weightlow. Normally, as one reduces the overall basis weight of the reusable,non-adhesive protective cover 10″, one reduces the cost to manufacturethe reusable, non-adhesive protective cover 10″.

The reusable, non-adhesive protective cover 10″ is similar to thereusable, non-adhesive protective cover 10′, shown in FIGS. 3 and 4,except that it has four layers 12, 14, 26 and 28, instead of the threelayers 12, 14 and 26. The reusable, non-adhesive protective cover 10″ isalso shown as a rectangular sheet having a longitudinal central axisX-X, a vertical central axis Y-Y and a transverse central axis Z-Z.Although depicted as a rectangular sheet, the reusable, non-adhesiveprotective cover 10″ could be manufactured in a variety of geometricalshapes, including, but not limited to: a square, a circle, a triangle,etc.

In the reusable, non-adhesive protective cover 10″, the exterior surface18 of the first layer 12 is designed to contact a structure or objectand is sometimes referred to as the “contact surface”. The exteriorsurface 22 of the second layer 14 is spaced away from the structure orobject which is to be covered and is sometimes referred to as the“non-contact surface”.

The third and/or fourth layers, 26 and/or 28 respectively, can alsocontain a colorant if desired. When desired, from between about 0.5% toabout 3% of a colorant can be added to either of the third or fourthlayers, 26 and 28 respectively.

Referring now to FIGS. 7 and 8, a reusable, non-adhesive protectivecover 10′″ is shown that includes a total of thirteen layers. Thethirteen layers include a first layer 12, a second layer 14, and eleveninner layers 30, 32, 34, 36, 38, 40, 42, 44, 46, 48 and 50 positionedbetween the first and second layers, 12 and 14 respectively, A surfaceof the layer 30 contacts the interior surface 16 of the first layer 12and a surface of the layer 50 contacts the interior surface 20 of thesecond layer 14.

It should be understood that from between two to eleven inner layers canbe positioned between the first and second layers, 12 and 14respectively.

The eleven inner layers 30, 32, 34, 36, 38, 40, 42, 44, 46, 48 and 50can be formed from the same or a different material, i.e. polymer,copolymer or homopolymer, as was used to create either of the first orsecond layers, 12 or 14 respectively, None of the eleven inner layers30, 32, 34, 36, 38, 40, 42, 44, 46, 48 and 50 has to have a moderate orhigh static coefficient of friction (SCOF) value and therefore nochemical or substance, such as Kraton®, has to be added to any of theselayers. Each of the eleven inner layers 30, 32, 34, 36, 38, 40, 42, 44,46, 48 and 50 can contain a flame retardant, if desired. The presence ofa flame retardant is optional. When a flame retardant is desired,Extensity 0201-127 or some other flame retardant chemical or substancecan be added to one or more of the eleven inner layers 30, 32, 34, 36,38, 40, 42, 44, 46, 48 and 50. Desirably, a flame retardant can be addedto any or all of the eleven inner layers 30, 32, 34, 36, 38, 40, 42, 44,46, 48 and 50. The amount of the flame retardant that is added can vary.Normally, at least about 5% of a flame retardant can be added to one ormore of the eleven inner layers 30, 32, 34, 36, 38, 40, 42, 44, 46, 48and 50, Desirably, at least about 8% of a flame retardant can be addedto one or more of the eleven inner layers 30, 32, 34, 36, 38, 40, 42,44, 46, 48 and 50. More desirably, at least about 10% of a flameretardant can be added to one or more of the eleven inner layers 30, 32,34, 36, 38, 40, 42, 44, 46, 48 and 50. Even more desirably, at leastabout 12% of a flame retardant can be added to one or more of the eleveninner layers 30, 32, 34, 36, 38, 40, 42, 44, 46, 48 and 50. Mostdesirably, each of the two to eleven inner layers 30, 32, 34, 36, 38,40, 42, 44, 46, 48 and 50 can contain from between about 5% to about 20%of a flame retardant.

The thickness (not designated) of each of the eleven inner layers 30,32, 34, 36, 38, 40, 42, 44, 46, 48 and 50 can vary in dimension. Thethickness of each of the eleven inner layers 30, 32, 34, 36, 38, 40, 42,44, 46, 48 and 50 can be less than, equal to or be greater than eitherof the thicknesses t₁ or t₂ of the first or second layers, 12 or 14respectively, Normally, the thickness of each of the eleven inner layers30, 32, 34, 36, 38, 40, 42, 44, 46, 48 and 50 is equal to or greaterthan either of the thicknesses t₁ or t₂ of the first or second layers,12 or 14 respectively. Each of the eleven inner layers 30, 32, 34, 36,38, 40, 42, 44, 46, 48 and 50 can have a thickness which range frombetween about 2 mils to about 20 mils (about 0.002 inches to about 0.020inches). Desirably, each of the eleven inner layers 30, 32, 34, 36, 38,40, 42, 44, 46, 48 and 50 has a thickness greater than about 3 mils(about 0.003 inches). More desirably, each of the eleven inner layers30, 32, 34, 36, 38, 40, 42, 44, 46, 48 and 50 has a thickness greaterthan about 5 mils (about 0.005 inches), Even more desirably, each of theeleven inner layers 30, 32, 34, 36, 38, 40, 42, 44, 46, 48 and 50 has athickness greater than about 6 mils (about 0.006 inches). Mostdesirably, each of the eleven inner layers 30, 32, 34, 36, 38, 40, 42,44, 46, 48 and 50 has a thickness greater than about 7 mils (about 0.007inches).

Each of the one to eleven inner layers 30, 32, 34, 36, 38, 40, 42, 44,46, 48 and 50 can be formed from any material, i.e. polymer, copolymer,homopolymer, or from any other material known to those skilled in theart. Each of the one to eleven inner layers 30, 32, 34, 36, 38, 40, 42,44, 46, 48 and 50 can be made from a low cost material, such as arecycled polymer, to reduce the total cost of the reusable, non-adhesiveprotective cover 10″. Alternatively, one or more of the eleven innerlayers 30, 32, 34, 36, 38, 40, 42, 44, 46, 48 and 50 can be foam. Onesuch foam is formed from polyethylene, which will increase the overallthickness of the reusable, non-adhesive protective cover 10′″ whilekeeping the overall basis weight low. Normally, as one reduces theoverall basis weight of the reusable, non-adhesive protective cover10′″, one reduces the cost to manufacture the reusable, non-adhesiveprotective cover 10′″.

The reusable, non-adhesive protective cover 10′″ is similar to thereusable, non-adhesive protective cover 10″, shown in FIGS. 5 and 6,except that it has thirteen layers 12, 14, 30, 32, 34, 36, 38, 40, 42,44, 46, 48 and 50, instead of the four layers 12, 14, 26 and 28. Thereusable, non-adhesive protective cover 10′″ is also shown as arectangular sheet having a longitudinal central axis X-X, a verticalcentral axis Y-Y and a transverse central axis Z-Z. Although depicted asa rectangular sheet, the reusable, non-adhesive protective cover 10′″could be manufactured in a variety of geometrical shapes, including, butnot limited to: a square, a circle, a triangle, etc.

In the reusable, non-adhesive protective cover 10′″, the exteriorsurface 18 of the first layer 12 is designed to contact a structure orobject and is sometimes referred to as the “contact surface”. Theexterior surface 22 of the second layer 14 is spaced away from thestructure or object which is to be covered and is sometimes referred toas the “non-contact surface”.

The one to eleven inner layers 30, 32, 34, 36, 38, 40, 42, 44, 46, 48and 50 can also contain a colorant, if desired. When desired, from about0.5% to about 3% of a colorant can be added to any one or all of theeleven inner layers 30, 32, 34, 36, 38, 40, 42, 44, 46, 48 and 50.

Referring now to FIGS. 9 and 10, a reusable, non-adhesive protectivecover 11 is shown. The reusable, non-adhesive protective cover 11 issimilar to the reusable, non-adhesive protective cover 10, shown inFIGS. 1 and 2, except that it contains a plurality of indentations 52 inFIG. 10 and a plurality of protrusions 54. The plurality of indentations52 appear in the exterior surface 18 of the first layer 12 and theplurality of protrusions 54 appear in the exterior surface 22 of thesecond layer 14. As depicted in FIG. 10, each of the indentations 52 isvertically aligned, parallel to the transverse central axis Z-Z with oneof the plurality of protrusions 54. Each of the indentations 52 is amirror image of each of the protrusions 54, The size, shape andconfiguration of each of the indentations 52 and protrusions 54 canvary. Each of the plurality of indentations 52 and each of the pluralityof protrusions 54 can have almost any known geometrical shape or design.All of the plurality of indentations 52 can have an identicalconfiguration or some of the indentations 52 can have a differentconfiguration. Likewise, all of the plurality of protrusions 54 can havean identical configuration or some of the protrusions 54 can have adifferent configuration. In FIGS. 9 and 10, the plurality of protrusions54 form a pattern. The pattern includes a plurality of elongated, narrowshapes with pointed ends. This pattern is commonly referred to by avariety of names such as: “diamond plate, checquer plate, tread plate orDurbar floor plate”. This pattern appears as a series of raised diamondsor lines. This pattern is typically used on the steps of a fire truck,on stairways, etc.

Referring to FIG. 10, each of the indentations 52 has a depth d whichextends into the reusable, non-adhesive protective cover 11. The depth dis measured from that portion of the exterior surface 18 of the firstlayer 12 that is planar to the bottom of the indentation 52. The depth dcan vary in dimension. Likewise, each of the protrusions 54 has a heighth which extends outward from the reusable, non-adhesive protective cover11. The height h is measured from that portion of the exterior surface22 of the second layer 14 that is planar to the top of the protrusion54. The height h can vary in dimension. Generally, the depth d is equalto the height h. Both the depth d and the height h can range frombetween about 0.01 mil to about 5 mils. Desirably, both the depth d andthe height h can range from between about 0.02 mils to about 3 mils.More desirably, both the depth d and the height h can range from betweenabout 0.03 mils to about 2 mils. Even more desirably, both the depth dand the height h can range from between about 0.04 mils to about 1 mil.Most desirably, both the depth d and the height h can each exceed about0.05 mils.

The plurality of protrusions 54 function to improve the slip resistanceof the reusable, non-adhesive protective cover 11 when it is positionedover flooring which may be damp or wet. The raised areas of theplurality of protrusions 54 provide dry areas which prevent a personwalking on the reusable, non-adhesive protective cover 11 from slipping.The plurality of protrusions 54 also facilitate the unwinding of afinished roll prior to use. The plurality of protrusions 54 actuallyprevent blocking of the roll of the reusable, non-adhesive protectivecover 11.

Methods

Referring now to FIGS. 11-16, several methods of forming a reusable,non-adhesive protective cover 10, 11 or 11′ will now be explained.

Referring to FIG. 11, a method of forming a co-extruded embossed,reusable, non-adhesive protective cover 11 is shown. The method includesthe steps of extruding a first layer 12 from a first extruder 56 onto arotatable cast roll 58. The cast roll 58 rotates in a counterclockwisedirection. The first layer 12 is a thermoplastic film formed from apolymer, copolymer, homopolymer, etc. For example, the first layer 12could be a copolymer film of low density polyethylene and Kraton®. Thefirst layer 12 has an interior surface 16 and an exterior surface 18.The first layer 12 contains from between about 5% to about 20% of aflame retardant (not shown). The first layer 12 has a static coefficientof friction (SCOF) of at least about 0.5. In one particular example, thefirst layer 12 contains from between about 18% to about 20% of lowdensity polyethylene film, about 70% hydrogenated styrene blockcopolymer, and from between about 10% to about 12% of a flame retardant.

The method also includes extruding a second layer 14 from a secondextruder 60 onto the interior surface 16 of the first layer 12 to form aco-extruded thermoplastic laminate 24. The second layer 14 is also athermoplastic film formed from a polymer, copolymer, homopolymer, etc.For example, the second layer 14 could be a linear low densitypolyethylene film. In one particular example, the second layer 14contains from between about 77% to about 79% of linear low densitypolyethylene film, about 10% of linear low density polyethylene, about10% of a flame retardant, and from between about 1% to about 3% of acolorant.

The second layer 14 has an exterior surface 22 which exhibits“attachment and release” capabilities such that a Duct (joint) tape canbe used to join adjacent sheets of the reusable, non-adhesive protectivecover 11, 11 together. The second layer 14 contains from between about5% to about 20% of a flame retardant.

The co-extruded laminate 24 is then advanced between a nip 62 formed byan embossing roll 64 and a rubber roll 66. The embossing roll 64 isrotated in a clockwise direction and the rubber roll 66 is rotated in acounter clockwise direction. The nip 62 can be sized to allow thereusable, non-adhesive protective cover 11 to pass therethrough. Theexterior surface 18 of the first layer 12 contacts the embossing roll 64to form a co-extruded embossed thermoplastic laminate 24. The embossingroll 64 forms a plurality of indentations 52 in the exterior surface 18of the first layer 12 and a plurality of protrusions 54 in the exteriorsurface 22 of the second layer 14, see FIGS. 9 and 10.

The method further includes passing the co-extruded embossed laminate 24around at least a portion of a chill roll 68 to cool the laminate 24 andform the co-extruded embossed, reusable, non-adhesive protective cover11. The chill roll 68 rotates in a counterclockwise direction, A guideroll 70 and a doctor blade (not shown), or some other removal mechanismknown to those skilled in the art, can be used to remove the co-extrudedembossed, reusable, non-adhesive protective cover 11 from the chill roll68. The co-extruded embossed, reusable, non-adhesive protective cover 11is free of polyvinyl chloride. The co-extruded embossed, reusable,non-adhesive protective cover 11 can then be rolled up on a spindle andbe placed in storage or be shipped to a customer.

Referring now to FIG. 12, a second method is shown for producing aco-extruded embossed, reusable, non-adhesive protective cover 11′. Thismethod utilizes a manifold extruder 72. In this method, a first polymer(not shown) is routed through a first line 74 into the manifold extruder72 and a second polymer (not shown) is routed through a second line 76into the manifold extruder 72. The first and second polymers can besolid resin pellets which are heated to a semi-solid or viscous state.In the manifold extruder 72, the first and second polymers are extrudedas distinct layers onto the cast roll 58. The remainder of this methodis identical to that described above for the method shown in FIG. 11,This method forms a manifold co-extrusion, embossed, reusable,non-adhesive protective cover 11′.

It should be understood that a reusable, non-adhesive protective cover11′, having three or more layers, can be produced using the manifoldapparatus and method depicted in FIG. 12.

Referring now to FIG. 13, a third method is shown for producing anon-embossed, co-extruded, reusable, non-adhesive protective cover 10.This method is similar to that shown in FIG. 11 except the embossingroll 64 and the rubber roll 66 are removed, Because of this, thenon-adhesive protective cover 10 is not embossed.

Referring to FIG. 14, a fourth method is shown for forming anon-embossed, film extrusion coat, reusable, non-adhesive protectivecover 10. This method is similar to that shown in FIG. 13 except insteadof using a second extruder 60, a thermoplastic film layer 78 is directedby a guide roll 80 onto the interior surface 16 of the first layer 12.The guide roll 80 rotates in a clockwise direction. The thermoplasticfilm layer 78 can be formed from a polymer, copolymer, homopolymer, etc.For example, the thermoplastic film layer 78 could be a low densitypolyethylene film. Since the embossing roll 64 and the rubber roll 66have been removed, the non-adhesive protective cover 10 will not beembossed.

Referring to FIG. 15, another method of making a non-embossed,coextruded film, non-adhesive protective cover 11″ is shown. This methodstarts out the same as that shown in FIG. 12. In the manifold extruder72, the first and second polymers are extruded as distinct layers ontothe smooth steel roll 84, The distinct layers are directed between a nip82 formed by a smooth steel roll 84 and a rubber backing roll 86. Thesmooth steel roll 84 rotates in a counterclockwise direction and therubber backing roll 86 rotates in a clockwise direction. The size of thenip 82 can vary. After passing through the nip 82 the film is directedaround at least a portion of the circumference of a pair of chill rolls88 and 90. The chill roll 88 rotates in a clockwise direction and theother chill roll 90 rotates in a counterclockwise direction. The pair ofchill rolls 88 and 90 can be vertically arranged. After being chilled,the reusable, non-adhesive protective cover 11″ can be routed to awindup station (not shown) where it can be accumulated into rolls ofvarious diameters.

Lastly, referring to FIG. 16, another method of making an embossed,coextruded film, non-adhesive protective cover 11′″ is shown. Thismethod is similar to that depicted in FIG. 15 except the smooth steelroll 84 is replaced with an embossing roll 92. The embossing roll 92will emboss the film as it passes through the nip 82.

While the invention has been described in conjunction with severalspecific embodiments, it is to be understood that many alternatives,modifications and variations will be apparent to those skilled in theart in light of the foregoing description. Accordingly, this inventionis intended to embrace all such alternatives, modifications andvariations which fall within the spirit and scope of the appendedclaims.

We claim:
 1. A method of forming a reusable, co-extruded embossednon-adhesive protective cover, comprising the steps of: a) extruding afirst layer of a thermoplastic film onto a rotatable cast roll, saidfirst layer containing from between about 18% to about 20% of lowdensity polyethylene film, about 70% hydrogenated styrene blockcopolymer, and from between about 10% to about 12% of a flame retardant,said first layer having an interior surface and an exterior surface, b)extruding a second layer of a thermoplastic film onto said interiorsurface of said first layer to form a co-extruded laminate, said secondlayer having an exterior surface exhibiting attachment and releasecapabilities such that a joint tape can be used to join adjacent sheetsof the reusable, non-adhesive protective cover together; c) advancingsaid co-extruded laminate between a nip formed by an embossing roll anda rubber roll, said exterior surface of said first layer contacting saidembossing roll to form a co-extruded embossed laminate; and d) passingsaid co-extruded embossed laminate around at least a portion of a chillroll to cool said laminate and form said reusable, co-extruded embossednon-adhesive protective cover, said cover being free of polyvinylchloride.
 2. The method of claim 1 wherein said first layer has a staticcoefficient of friction of at least about 0.5.
 3. The method of claim 1wherein said first layer is a different material than said second layer.4. The method of claim 1 wherein said second layer contains from betweenabout 77% to about 79% of linear low density polyethylene film, about10% of linear low density polyethylene, about 10% of a flame retardant,and from between about 1% to about 3% of a colorant.
 5. The method ofclaim 1 wherein said embossing roll forms a plurality of indentations insaid exterior surface of said first layer.
 6. The method of claim 1wherein said embossing roll forms a plurality of protrusions in saidexterior surface of said second layer.
 7. The method of claim 1 whereinsaid first layer is a copolymer film of low density polyethylene and astyrene block copolymer.
 8. The method of claim 1 wherein said secondlayer contains from between about 5% to about 20% of a flame retardant.9. The method of claim 1 wherein said rubber roll rotates in a counterclockwise direction.
 10. A method of forming a reusable, co-extrudedembossed non-adhesive protective cover, comprising the steps of: a)extruding a first layer of a thermoplastic film onto a rotatable castroll, said first layer having an interior surface and an exteriorsurface, said first layer containing from between about 5% to about 20%of a flame retardant; b) extruding a second layer of a thermoplasticfilm onto said interior surface of said first layer to form aco-extruded laminate, said second layer containing from between about77% to about 79% of linear low density polyethylene film, about 10% oflinear low density polyethylene, about 10% of a flame retardant, andfrom between about 1% to about 3% of a colorant, said second layerhaving an exterior surface exhibiting attachment and releasecapabilities such that a joint tape can be used to join adjacent sheetsof the reusable, non-adhesive protective cover together, c) advancingsaid co-extruded laminate between a nip formed by an embossing roll anda rubber roll, said exterior surface of said first layer contacting saidembossing roll to form a co-extruded embossed laminate; and d) passingsaid co-extruded embossed laminate around at least a portion of a chillroll to cool said laminate and form said reusable, co-extruded embossednon-adhesive protective cover, said cover being free of polyvinylchloride.
 11. The method of claim 10 wherein said first layer has astatic coefficient of friction of at least about 0.5.
 12. The method ofclaim 10 wherein said cast roll rotates in a counter clockwisedirection.
 13. The method of claim 10 wherein said embossing rollrotates in a clockwise direction.
 14. The method of claim 10 whereinsaid first layer contains from between about 18% to about 20% of lowdensity polyethylene film, about 70% hydrogenated styrene blockcopolymer, and from between about 10% to about 12% of a flame retardant.15. The method of claim 10 wherein said second layer is a differentmaterial than said first layer.
 16. A method of forming a reusable,co-extruded embossed non-adhesive protective cover, comprising the stepsof: a) extruding a first layer of a thermoplastic film onto a rotatablecast roll, said first layer containing from between about 18% to about20% of low density polyethylene film, about 70% hydrogenated styreneblock copolymer, and from between about 10% to about 12% of a flameretardant, said first layer having an interior surface and an exteriorsurface, and said first layer having a static coefficient of friction ofat least about 0.5; b) extruding a second layer of a thermoplastic filmonto said interior surface of said first layer to form a co-extrudedlaminate, said second layer having an exterior surface exhibitingattachment and release capabilities such that a joint tape can be usedto join adjacent sheets of the reusable, non-adhesive protective covertogether, and said second layer contains from between about 5% to about20% of a flame retardant; c) advancing said co-extruded laminate betweena nip formed by an embossing roll and a rubber roll, said exteriorsurface of said first layer contacting said embossing roll to form aco-extruded embossed laminate; and d) passing said co-extruded embossedlaminate around at least a portion of a chill roll to cool said laminateand form said reusable, co-extruded embossed non-adhesive protectivecover, said cover being free of polyvinyl chloride.
 17. The method ofclaim 16 wherein a first polymer is routed through a first line to amanifold extruder and a second polymer is routed through a second lineto said manifold extruder, and in said manifold extruder said first andsecond polymers are extruded as distinct layers onto said rotatable castroll.
 18. The method of claim 16 wherein the first layer, the secondlayer and the third layer can be extruded onto said rotatable cast rollusing a manifold extruder.
 19. The method of claim 16 wherein said firstlayer is a different material than said second layer.
 20. The method ofclaim 16 wherein said second layer contains from between about 77% toabout 79% of linear low density polyethylene film, about 10% of linearlow density polyethylene, about 10% of a flame retardant, and frombetween about 1% to about 3% of a colorant.